operation & maintenance instruction

Operation & Maintenance Instruction

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NOTE: The following description andoperation is based on this device andits components being new or thisdevice and its components havingbeen repaired, tested, installed andmaintained in accordance withinstructions issued by this and anyother applicable Wabtec Corporationpublications.

WARNING: At the time any part isreplaced in this device, the operation ofthe complete device must pass aseries of tests prescribed in the latestissue of the applicable Wabtec TestSpecification. At the time this device isapplied to the brake equipmentarrangement, a stationary vehicle testmust be made to ensure that this devicefunctions properly in the total brakeequipment arrangement. (Consult yourlocal Wabtec CorporationRepresentative for identity of the testspecification, with latest revision date,that covers this device.)

IMPORTANT: Only Wabtec Corporationsupplied parts are to be used in therepair of this device in order to obtainsatisfactory operation. Commerciallyavailable non-O.E.M. parts areunacceptable.

NOTE: The part numbers and theirassociated descriptions are theproperty of Wabtec Corporation and maynot be replicated in any manner or formwithout the prior sole written consent ofan Officer of Wabtec Corporation.

ABDX®-SS CONTROL VALVE, PART NO. 664742

ABDX®-SS ALUMINUM SERVICE PORTIONABDX®-SS ALUMINUM EMERGENCY PORTION

AUGUST, 2003

® Registered Trademark of Wabtec Corporation© 2003 WABCO Freight Car Products. A Wabtec Company. All rights reserved

IMPORTANT: This valve is NOT to be applied to freight cars that are assigned toInterchange Service on the North America Continent Railroads.


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1.0 DESCRIPTION

The AB Single Capacity Freight Car Air Brake Equipmentwith the ABDX Type Control Valve is functionally compatiblewith equipments using the AB, ABD or the ABDW ControlValve. Correct style of ABDX Control Valve must be appliedto specific length cars.

The ABDX Type Control Valve improves service braking byproviding both a shorter response time and a shorter brakecylinder pressure build up time. The initial quick servicefunction has been improved through a new service piston,diaphragm and diaphragm clamping arrangement.

Other benefits of the ABDX Type Control Valve includeimproved undesired emergency (UDE) protection, improvedprotection against leakage, and the elimination of the needfor auxiliary continuous quick service valves.

1.1 PARTS OF THE EQUIPMENT

The following is a description of the Control Valve which ispart of the AB Freight Car Air Brake Equipment with the ABDXType Control Valve:

1.1.1 ABDX TYPE CONTROL VALVE

The ABDX Type Control Valve controls the flow of air to andfrom the brake cylinder and to charge the reservoirs. It consistsof a Pipe Bracket, a Service Portion and an EmergencyPortion.

1.1.2 PIPE BRACKET

The ABDX Control Valve uses the AAR AB type pipe bracket.This is a two-face pipe bracket to which are mounted theservice and emergency portions. Figures 2 and 3 show theport identification on each face. The pipe bracket is semi-permanently bolted to the car. Pipe connections may be madeby means of adjustable welded fittings secured to machinedflange pads on the pipe bracket. No pipe connections needto be disturbed when removing or replacing the service oremergency portion. The pipe bracket contains the quick actionchamber and a removable strainer which provides long life byminimizing the passage of dirt particles to the valve and brakecylinder.

Pipe Connections - Figure 4 shows the pipe bracket faceto which the pipe connections are made. Each portconnection is identified by number and name.

Figure 1 - Diagrammatic View


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Figure 2 - Pipe Bracket Service FacePort Identification

Figure 3 - Pipe Bracket Emergency FacePort Identification

Figure 4 - Pipe Bracket Face Pipe Connections

e3

b

b4

c

c3c2

Q.A.C.

c4

c3 b2

EX

a

E2

b

Porta - To Auxillary Reservoirb - To Brake Pipeb2 - To Strainer Nut Cavityc3 - To Emergency Face and Branches c2 and c4c4 - To Passage c3e2 - To Emergency Reservoir and to Emergency FaceEX - To Retaining Valve

Portb - To Brake Pipeb4 - To Brake Pipe Passage bc - To Brake Cylinderc2 - To Passage c3c3 - To Service Face and Branch Ports c2 and c4e3 - To Emergency Reservoir and Service FaceQ.A.C. - To Quick Action Chamber

Port Designation Flange Size

1 Brake Pipe 1 inch2 Emergency Reservoir 3/4 inch3 Brake Cylinder 3/4 inch5 Auxiliary Reservoir 3/4 inch

10 Retainer 3/8 inch


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1.1.3 SERVICE PORTION

The Service Portion controls the flow of air from the auxiliaryreservoir to the brake cylinder during a service applicationand the recharging of the auxiliary and emergency reservoirs,and exhaust of brake cylinder during a release. Theaccelerated release feature speeds up the recharge of brakepipe during a release of a service application by the use of asmall amount of air from the emergency reservoir. The ServicePortion also includes a large capacity manual release valve.This release valve offers the choice of exhausting only thebrake cylinder, exhausting the auxiliary reservoir and brakecylinder, or exhausting both reservoirs and the brake cylinder.Figure 2 shows the port identification on the service portionbolting face. The ABDX-SS Service Portion has been tunedto optimize the Quick Service function for short cars.

1.1.4 EMERGENCY PORTION

The Emergency Portion controls the flow of air from bothreservoirs to the brake cylinder during an emergencyapplication. An emergency application can be obtained atany time regardless of the existing state of service applicationor release, provided brake pipe pressure has not been reducedbelow 45 psi prior to initiating an emergency. Emergencybrake cylinder air pressure is approximately 20% higher thanthat obtained from a full service brake application. Theemergency brake cylinder pressure is developed in twostages, thus reducing train slack action.

The Emergency Portion also contains the acceleratedapplication feature which accelerates the service buildup ofbrake cylinder pressure throughout the train by locally ventingbrake pipe at each car. The ABDX-SS Emergency Portion istuned to optimize this feature on short cars with less than 45feet of brake pipe.

The emergency accelerated release feature speeds up therecharge of brake pipe during a release of emergencyapplication by the use of air from the brake cylinder andauxiliary reservoir.

2.0 OPERATION

Refer to Wabtec Publication 5062-19 for the operation ofABDX-SS Control Valve.

3.0 MAINTENANCE SCHEDULE

IMPORTANT: The ABDX-SS Control Valve should beremoved from the equipment arrangement, taken to the shop,be completely disassembled, the parts cleaned, lubricated,assembled, using NEW Wabtec Corporation rubber partsand other specified NEW Wabtec Corporation parts. The valveis then tested according to the following vehicle applicationschedule, or more frequently if service conditions so indicate.

RECOMMENDED FREQUENCY AT LEASTTYPE OF APPLICATION ONCE EVERY

FREIGHT Not to exceed 12 YEARS

4.0 PARTS CATALOG INFORMATION

4.1 PARTS CATALOG

IMPORTANT: When ordering replacement parts for theABDX-SS Control Valve, Part No. 664742, or any of itscomponent portions, refer to the current issue of WabtecCorporation Parts Catalog 3225-50, S.6.

NOTE: The reference numbers used in this publication andthose used in the parts catalog may differ. Check thedescriptive parts name to be sure that the desired part isordered.

4.2 REPLACEMENT PARTS

IMPORTANT: To obtain satisfactory operation andreliability of the ABDX-SS Control Valve, ONLY WabtecCorporation replacement parts are to be used in themaintenance of the ABDX-SS Control Valve. Commerciallyavailable parts are unacceptable.

5.0 SAFETY PROCEDURES & WARNINGS

Regular car builder and/or owner-operating property and/orshop safety procedures MUST BE followed when performingany work on the ABDX-SS Control Valve and/or its componentparts.

The work area should be clean.


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WARNING: The following statements of warning apply,all or in part, wherever the symbol appears in themaintenance procedures. Failure to observe these precautionsmay result in serious injury to those performing the workand/or bystanders.

� Portions weigh in excess of 30 pounds. Use carewhen lifting and hauling portions to preclude injury.

� Due to the possibility of exhausting air, and highdecibel levels of noise associated with it, from thedevice during testing, it is recommended that sufficienthearing and eye protection be used. This is intendedto minimize the possibilities of hearing and eye injuryto the operator or persons near the test rack.

� The use of an air jet, which must be less than 30p.s.i.g., to blow parts clean or to blow them dry afterbeing cleaned with a solvent will cause particles ofdirt and/or droplets of the cleaning solvent to beairborne. Wire brushing may also cause particles ofdirt, rust and scale to become airborne. Theseconditions may cause skin and/or eye irritation.

� When using an air jet, do not direct it towardanother person. Improper use of air jet could result inbodily injury.

� Personal eye protection must be worn whenperforming any work on this device or its componentparts to avoid any possible injury to the eyes.

� The use of solvents and lubricants can involve healthand/or safety hazards. The manufacturers of the solventsand lubricants should be contacted for safety data (suchas OSHA Form OSHA-20 or its equivalent). Therecommended precautions and procedures of themanufacturers should be followed.

� When performing any test or work on devices orequipment while they are on the vehicle (on car testetc.) special precautions must be taken to ensure thatvehicle movement will not occur which could result ininjury to personnel and/or damage to equipment.

Figure 5 - ABDX-SS Control Valve, Part No. 664742

8

A

B

3

4

56

10

9

11

7

C

12

2

1

8


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� When performing the procedures which follow,springs within the assembly may be under load.Exercise care so that no parts are inadvertently expelled.Inadvertently expelled parts may cause bodily injury,and/or damage to parts.

� All air supply to this device and/or to any componentpart must be cut off and any air in the device be allowedto vent before this device and/or any component partis removed from the equipment arrangement.

� Bottled up air under pressure (even though airsupply is cut off) may cause gaskets and/or particles ofdirt to become airborne and an increase in sound levelwhen this device and/or any component part is removedfrom the equipment arrangement. Personal eye andear protection must be worn and care taken to avoidpossible injury when performing any work on this deviceand/or component part.

� An adequate support or lifting device must beavailable to support the device and/or valve portion(s)during removal, installation and maintenanceprocedures.

6.0 CLEANING SOLVENT, LUBRICANT & SEALANT

6.1 CLEANING SOLVENT

6.1.1 The means used to clean the reusable parts of theABDX-SS Type Control Valves MUST BE an aliphatichydrocarbon solvent, such as mineral spirits or naptha, or aheated aqueous biodegradable detergent and rinse.

IMPORTANT: Cleaning materials are to be used in a wellventilated area.

6.2 LUBRICANT

Lubricant Current AAR Specification

Triple Valve Oil M-912

Dry Graphite M-913

Brake Cylinder Lubricant M-914

6.2.1 The o-ring, o-ring grooves and the o-ring bearingsurfaces of the bushing(s) must be lubricated with Number 2Silicone Grease, Wabtec Corporation Specification M-07680-02 (Industry Designation MIL-G-4343), such as Dow CorningCorporation, Dow Corning 55.

6.2.2 The threads of choke plugs and all other removableplugs, as well as all other threaded parts which may later bedifficult to remove, must be pre-coated with a Loctite productcalled Vibraseal #517. The Vibraseal plugs are to be fullythreaded into place, however discretion should be used whentightening the choke plug, to facilitate removal.

6.3 SEALANT

6.3.1 Locking Sealant, Westinghouse Air Brake CompanySpecification M-07499-05, such as Loctite Corporation TL-242, is required for application to certain threads.

7.0 MAINTENANCE PROCEDURE

7.1 �ON-CAR� MAINTENANCE PROCEDURES

IMPORTANT: �ON-CAR� Maintenance is limited to theremoval and replacement of Component Portions. No �ON-CAR� repair of the valve is to be attempted.

7.1.2 SPECIAL TOOLS

IMPORTANT: The information shown in Figures 6 thru 11,for making tools, is furnished as a convenience. The WabtecCorporation shall have NO responsibility for tools which theydo not manufacture and will not be responsible for the resultswhen using any of the specified tools (including claims bythird parties).

7.2 PORTION REMOVAL & INSTALLATION - "ON CAR"

7.2.1 IMPORTANT: ALL car builder and owner-operating property safety procedures, in addition to warningsas listed in Section 5 of this publication, MUST BE adhered to.

7.2.2 IMPORTANT: The handbrake(s) of the carMUST BE applied and the wheels of the car chocked toprevent unintentional car movement. Warning placardsindicating that work is being performed are to be placed onand about the car.

7.2.3 IMPORTANT: ALL air flow to the ABDX-SSControl Valve MUST BE allowed to deplete and subsequentlybe cut off.


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Figure 8 - Service Piston Assembly Fixture

Figure 6 - Hand Tool for Diaphragm Installation Figure 7 - Mandrel for Installing O-rings

Piston or Spool Valve

O-rings

Mandrel

Air Hole

�

Graduating Valve Spring

Driver

Roll Pin

Section A-A

Slide Valve Spring

Slide Valve

Graduating Valve

Piston Stem

Slide Valve Spring

Fixture Back Plate

Jaws of Bench Vise

Fixture Body

Roll Pin in Place

AGraduating Valve

Fixture Back Plate

A

�

�

1/4�R

3/4�

3/4�

3/32�

Approx. 8�

1�

�

�

��

��

��

�

��

Material: Steel

Break Corners and Remove Burrs

��


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Figure 9 - Limiting Valve Piston Spanner Wrench Figure 10 - Service Accelerated Release ValvePiston Spanner Wrench

No. 23(0.154�) Drill (2

Holes)

9/64� Deep

Break Cornersand

Remove Burrs

23/4�

21/8� 5/16�

7/8�

41/4�

3/8�

1�

13/8�

23/4�

��

��

� �

�

�

��

��

5/32� x 9/32�Steel Dowel

Pin (2 Req�d)Press in Place

�

Material: Steel

To Be ManufacturedBy Customer

Figure 11 - Inshot Piston Spanner Wrench

11/4�

7/16� 7/16�

5/8�

1/4�

No. 43

(0.089�) Drill(2 Holes)

25/64� Drill3/32� x 5/16�

Steel Dowel Pin (2Req�d)

Press in Place

5�Material: Steel

Break Corners and Remove Burrs To Be Manufactured By Customer

5/8�

�

�

��

�

�

�

�

� �

��

�

�

5/16�

1/8� x 3/8�Steel Dowel Pin

(2 Req�d) Press in Place

Material: Steel

Break Corners and Remove Burrs

7/16� Drill

0.120� Drill (2 Holes)

31/64� 31/64�

3/4�

11/2�

6�

To Be Manufactured By Customer

3/4�

�

�

�

��

�

��

� �

�

�

�


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7.2.4 Emergency Portion Removal and InstallationSee Figure 5

7.2.4.1 Scrape, wipe and blow off with a jet of lowpressure air (less than 30 psi) all dirt adjacent to the gasketbetween the pipe bracket and emergency valve portion. Usingthe blower hose, blow off the emergency portion, pipe brackethopper slopes, car under frames, etc., to free them of allloose dirt that may otherwise get into the emergency portionor pipe bracket when the portion is being removed andreapplied.

7.2.4.2 Remove the vent protector from the failed emergencyportion and apply a WABCO Freight Car Products standardvent protector plug, as shown in Figure 17.

7.2.4.3 The cleaned emergency portion must be handledwith care to avoid entrance of dirt or water which coulddamage the internal parts.

IMPORTANT: The shipping cover must not be removedfrom the clean replacement emergency portion until it is readyto be mounted to the pipe bracket on the car.

7.2.4.4 Remove the Emergency Portion (1) from the PipeBracket Portion (7) by first removing the three 5/8� hex nuts(8) and apply a shipping cover, as shown in Figure 15, andtighten nuts.

7.2.4.5 Remove and SCRAP the Emergency PortionMounting Gasket (2) from the mounting face of the PipeBracket (7).

7.2.4.6 Visually inspect the Pipe Bracket Portion (7) fordamage. This portion need not be removed from theequipment arrangement unless it is damaged. If it isnecessary to remove the Pipe Bracket Portion (7), car builderand owner-operating property instructions are to be followed.

7.2.4.7 Inspect the Emergency Portion mounting face of thePipe Bracket Portion (7) to be sure that it is clean and is notdamaged or scratched. Be sure that ALL parts are cleanand unrestricted. If necessary, the ports can be blown outwith a low pressure jet of clean dry air. Exercise care so thatno dirt is blown into the ports or passages of the Pipe BracketPortion (7).

7.2.4.8 Apply a NEW WABCO Freight Car ProductsEmergency Portion Mounting Gasket (2) to the PipeBracket (7).

7.2.4.9 Remove the Vent Protector Plug from the new orsatisfactorily repaired and tested Emergency Portion (1).Install a cleaned or renewed Vent Protector into the newEmergency Portion (1).

WARNING: The ABDX-SS portions must not be appliedto cars exceeding 39 feet in length. Such incorrect applicationmay result in undesired brake action that could causeequipment damage and injury to bystanders.

7.2.4.10 Remove the shipping cover from the new orsatisfactorily repaired and tested Emergency Portion (1) andimmediately apply the Emergency Portion (1) to the PipeBracket (7). Coat the threads of the mounting studs lightlywith brake cylinder lubricant (M-914) or a compoundconsisting of one part graphite, Wabtec Specification [M-07695-02] (AAR Specification M-913), and two parts oil (SAE-20) by weight.

7.2.4.11 Tighten the three 5/8� hex nuts (8) evenly and firmlyin order to sufficiently prevent gasket leakage and yet notexcessively to cause distortion of the mounting gasket (2).

7.2.4.12 After the Emergency Portion (1) has beenreinstalled and all repairs have been completed, the entireair brake equipment must be tested in accordance with thelatest issue of the Code of Air Brake System Tests for FreightEquipment T-664742A/B-O.

7.2.5 Service Portion Removal and InstallationSee Figure 5

7.2.5.1 Disconnect the release valve handle or handles,leaving it attached to the release rod or rods.

7.2.5.2 Scrape, wipe and blow off with a jet of lowpressure air (less than 30 psi) all dirt adjacent to the gasketbetween the Pipe Bracket (7) and Service Portion (3). Usingthe blower hose, blow off the Service Portion (3), Pipe Bracket(7), hopper slopes, car underframe, etc., to free them of allloose dirt that may otherwise get into the Service Portion orPipe Bracket when the portion is being removed andreapplied.

7.2.5.3 The cleaned Service Portion (3) must be handledwith care to avoid entrance of dirt or water which could damagethe internal parts.


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7.2.5.4 IMPORTANT: The shipping cover must not beremoved from the clean replacement Service Portion until itis ready to be mounted to the Pipe Bracket on the car.

7.2.5.5 Remove the failed Service Portion (3) and apply theshipping cover and tighten nuts.

7.2.5.6 Apply standard or alternate stem guard (See Figure16) to the removed Service Portion and hold in place withcotter pin.

7.2.5.7 Remove Service Portion Mounting Gasket (4) anddiscard properly.

7.2.5.8 Remove the strainer nut (5) using strainer nut wrenchthen remove and discard the old air strainer (6).

7.2.5.9 Install a NEW air strainer (6). A wooden mandrel ofsuitable form will assist in guiding the strainer into properposition. Make certain its inner end is in engagement withthe sealing bead (if inserted properly, all nut threads will bevisible), then insert strainer nut (5) and tighten it firmly usingthe strainer nut wrench.

7.2.5.10 Install a NEW Service Portion MountingGasket (4).

WARNING: The ABDX-SS portions must not be appliedto cars exceeding 39 feet in length. Such incorrect applicationmay result in undesired brake action that could causeequipment damage and injury to bystanders.

7.2.5.11 Remove the shipping cover from the new orsatisfactorily repaired and tested Service Portion (3) andimmediately apply the portion to the Pipe Bracket (7). Coatthe threads of the mounting studs lightly with brake cylinderlubricant (M-914) or a compound consisting of one partgraphite, Wabtec Specification M-07695-02 (AARSpecification M-913), and two parts oil (SAE-20) by weight.

7.2.5.12 Tighten the three 5/8� hex nuts (8) evenly andfirmly in order to sufficiently prevent gasket leakage and yetnot excessively to cause distortion of Mounting Gasket (4).

7.2.5.13 Remove release valve stem guard from the newor repaired service portion and reconnect the release valvehandle or handles (which has been left attached to releaserod) to release valve handle end plate with a new cotter pin.

7.2.5.14 After the Service Portion has been reinstalledand all repairs have been completed, the entire air brakeequipment must be tested in accordance with the latest issueof the Code of Air Brake System Tests for Freight EquipmentT-664742A/B-O.

7.3 "IN-SHOP" MAINTENANCE PROCEDURES

IMPORTANT: The procedures which follow are to beperformed in the repair shop. To obtain satisfactory operationand reliability of this device only replacement parts suppliedby Wabtec Corporation are to be used in the maintenance ofthis device.

IMPORTANT: When performing the procedures whichfollow, DO NOT use hard or sharp metal tools to removegaskets, o-rings, the dust boot, or diaphragm. Exercise careso that no damage is done to parts.

WARNING: When performing the procedures whichfollow, springs within the assembly may be under load.Exercise care so that no parts are inadvertently expelled.Inadvertently expelled parts may cause bodily injury, and/ordamage to parts.

7.4 DISASSEMBLY of ABDX-SS EMERGENCY PORTIONSee Figure 12

7.4.1 Remove the vent protector assembly from theemergency portion body (58) if it is still in place. The ventprotector assembly is not illustrated in Figure 12.

7.4.2 Small Vent Valve Piston, Inshot Check Valve

7.4.3 Depress the spring retainer (28) into the body (58)and tilt it so that it is free of the retaining lip in the body(58) and remove the retainer (28), vent valve spring (29),and the small vent valve (23) from the body (58).

7.4.4 Depress the spring retainer (25) into the body (58)and tilt it so that it is free of the retaining lip in the body (58)and remove the retainer (25), inshot check valve spring (26),and the check valve (27) from the body (58). SCRAP thecheck valve (27).

7.4.5 Emergency Diaphragm Piston, High Pressure Spool,Emergency Accelerated Release Check Valve


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Figure 12 - ABDX-SS Aluminum Emergency Portion

1

3

4

5

10

11

27

76

89

12

28

29

24

25

26

5755 & 56

54

54

48

4958

46

47

45

43

44

42

41

40

39

38

37

32

30

31

3433

35

54

51, 52

& 53

36

59, 60

& 61

14

1615

13

2021

19

18

17

23

22

23

2

50

62


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7.4.6 Remove the four 1/2" x 13/4" hex head screws (1)which secure the top cover (2) to the body (58). Remove thecover (2).

7.4.7 Remove and SCRAP the ring gaskets (22, 23, 24)from the top cover (2).

NOTE: The thimble type air strainer (21) can be removed byfirst removing the retaining ring (20) from the body (58).

7.4.8 Remove the emergency accelerated release checkvalve spring (17), check valve spring seat (18), emergencyaccelerated release check valve (19), retaining ring (20), andthe thimble type air strainer (21) from the body (58). SCRAPthe check valve (19).

7.4.9 Remove the high pressure spool valve return spring(13) and the high pressure spool valve with o-rings (16, 15)from the body (58).

NOTE: For easier removal, thread a 3/8-16 cap screw intothe high pressure spool.

7.4.10 Remove and SCRAP the five 13/16" O.D. o-rings (15)from the high pressure valve (16).

7.4.11 Carefully remove the emergency diaphragm pistonassembly (3 to 12) as a unit from the body (58).

7.4.12 Carefully drift the 3/32" x 3/4" cylindrical spring pin (6)from the emergency slide valve (8). Remove the emergencyslide valve (8), filter (9), and spring (7) from the emergencypiston (10).

7.4.13 Remove the 5/8" x 1" hex head cap screw (3) thatsecures the diaphragm follower (4) and diaphragm (5) to theemergency piston (10). Remove follower (4) and diaphragm(5) from the piston (10). SCRAP the diaphragm (5).

7.4.14 Remove and SCRAP the two emergency wear rings(11 and 12) from the emergency piston (10).

7.4.15 Vent Valve, Inshot Piston, Emergency AcceleratedRelease Spool

7.4.16 Remove the two 1/2� x 11/8� hex head cap screws (31)and the 1/2� x 13/4� hex head cap screw (32) that secures thevent valve cover (33) to the body (58).

7.4.17 Remove the inshot piston spring (38) and the inshotpiston assembly (39 to 43) from the body (58).

7.4.18 Remove and SCRAP the 15/16" O.D. ring gasket (34)and the 5/8" O.D. ring gasket (35) from the vent valve cover(33).

7.4.19 Remove and SCRAP the 3/8" O.D. o-ring (40) fromthe inshot piston (41).

7.4.20 Use the inshot piston spanner wrench, as shown inFigure 9, to hold the inshot piston (43), then remove the 3/8"self-locking hex nut (39) from the piston (43). SCRAP thenut (39).

7.4.21 Remove the diaphragm follower (40) and diaphragm(41) from the piston (43). SCRAP the diaphragm (41).

7.4.22 Remove the vent valve piston diaphragm (36) andthe vent valve piston (37) from the body (58). SCRAP thediaphragm (36).

WARNING: The cap nut (45) is under spring load.Exercise care so that no parts are inadvertently expelledfrom the assembly. Inadvertently expelled parts may causebodily injury.

7.4.23 Using a 7/8" square wrench, remove the cap nut witho-ring (45, 44), which secures the emergency acceleratedrelease spool valve spring (46) and emergency acceleratedrelease spool valve (48) with o-rings (47) in the body (58).

7.4.24 Remove the emergency accelerated release spoolvalve spring (46) and emergency accelerated release spoolvalve (48) with o-rings (47) from the bottom of the body (56).

7.4.25 Remove and SCRAP the four 11/2" O.D. o-rings (47)from the spool valve (48).

7.4.26 Remove and SCRAP the 11/2" O.D. o-ring (44) fromthe cap nut (45).

7.5 ASSEMBLY of ABDX-SS EMERGENCY PORTIONSee Figure 12

7.5.1 Emergency Diaphragm Piston, High Pressure Spool,Emergency Accelerated Release Check Valve


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7.5.2 Using #2 Silicone Grease, Wabtec CorporationSpecification M-07680-02, coat the surfaces of four NEW11/2" O.D. o-rings (47). Also, lightly lubricate the o-ring groovesof the emergency accelerated release spool valve (48) andthe spool valve bushing surfaces of the body (58).

7.5.3 Install the four NEW, lubricated 11/2" O.D. o-rings(47) into their grooves on the emergency accelerated releasespool valve (48).

7.5.4 Install the emergency accelerated release spoolvalve (48) with o-rings (47) into its bush in the body (58),closed end first.

7.5.5 Install the emergency accelerated release spoolvalve spring (46) into the spool valve (48).

7.5.6 Apply #2 Silicone Grease, Wabtec CorporationSpecification M-07680-02, to the surfaces of a NEW 11/2"O.D. o-ring (44) and lightly lubricate the o-ring groove of thecap nut (45).

7.5.7 Install the NEW lubricated 11/2" O.D. o-ring (44) intoits groove on the cap nut (45).

7.5.8 Install the cap nut with o-ring (45 & 44) into the body(58) to secure the spring (46) and accelerated release spoolvalve (48) with o-rings (47) in place. Using a 7/8" square wrench,tighten the cap nut (45) between 55 and 65 foot-pounds oftorque.

7.5.9 Install the emergency wear rings (11 & 12) on theemergency piston (10).

IMPORTANT: Care should be taken when expanding oropening the wear rings during installation onto the emergencypiston. Do not overexpand the rings causing them to deformwhich would result in difficult installation of the piston intothe bore. The protective ring should be installed with the gapfacing the slide valve area of the emergency piston. Thepositioning of the rings will ease the assembly.

7.5.10 Install a NEW emergency piston diaphragm (5) onthe emergency piston (10) so that the piece number on thediaphragm is facing away from the piston.

7.5.11 Lightly coat the threads of the 5/8" x 1" hex headscrew (3) with LOCTITE Sealant TL-242, Wabtec CorporationSpecification M-07499-05. Install the cap screw (3) throughthe diaphragm follower (4) and into the piston (10) to secure

the piston (10), diaphragm (5) and follower (4) together. Handtighten the cap screw (3) and flip the diaphragm (5) in theopposite direction so that the large cone shaped opening isfacing the piston (10). Torque the screw (3) between 45 and50 foot-pounds.

7.5.12 Insert the emergency slide valve spring (7) into theemergency slide valve (8).

7.5.13 Carefully place the emergency slide valve with spring(8 & 7) on the stem of the piston (10) and secure the parts inplace by installing the 3/32" x 3/4" cylindrical spring pin (6).

7.5.14 Using a foam-tipped applicator, evenly spread a lightcoating of Triple Valve Oil, Wabtec Corporation SpecificationM-07611-20, (AAR Specification M-912) over the face of theemergency slide valve (8).

7.5.15 Evenly spread a light coating of the Triple Valve Oilon the slide valve bushing seat of the body (58).

7.5.16 Evenly spread a light coating of Triple Valve Oil overthe guide portion of the stem and piston end of the piston (10).

IMPORTANT: Care must be taken when compressing theslide valve spring (7) in preparation for inserting the emergencypiston assembly (3 to 10) into the body bushing. While usingminimal force, the assembly must be aligned squarely toprevent any wedging or distortion. The slide valve face (8)must be retracted from the bushing face as long as possible.

7.5.17 Install the diaphragm - piston - emergency slide valveassembly (3 to 10) into the body (58). Exercise care so thatNO damage is done to the emergency slide valve bushingseat.

7.5.18 Using the pressure of the thumb or finger, positionthe sealing bead of the diaphragm in the diaphragm beadgroove of the body (58).

7.5.19 Coat the surfaces of five NEW 13/16" O.D. o-rings(15) with #2 Silicone Grease, Wabtec CorporationSpecification M-07680-02. Also lightly lubricate the o-ringgrooves of the high pressure spool valve (16) and the bearingsurfaces of the spool valve bushing of the body (58).

7.5.20 Install the five NEW lubricated 13/16" O.D. o-rings(15) into their grooves on the high pressure spool valve (16).


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7.5.21 Install the high pressure spool valve with o-rings (16,15) into the body (58).

7.5.22 Install the high pressure spool valve return spring(13) into the high pressure spool valve (16).

7.5.23 Install a NEW thimble type air strainer (21) into theemergency accelerated check valve seat of the body (58).Secure the thimble type air strainer (21) into the body (58)with the retaining ring (20).

7.5.24 Install a NEW emergency accelerated release checkvalve (19) and check valve spring seat (18) and the checkvalve spring (17) into the body (58).

7.5.25 Install a NEW 13/4" O.D. ring gasket (22), two NEW11/2" O.D. ring gaskets (23) and a NEW 11/8" O.D. ring gasket(24) into their grooves in the top cover (2).

7.5.26 Place the top cover assembly (2) with ring gaskets(22, 23, 24) on the body (58) making sure that the diaphragm(5) and ring gaskets (22, 23, 24) remain in position.

7.5.27 Secure the cover (2) to the body (58) by installingthe four 1/2" x 13/4" hex head screws (1). Torque the screwsbetween 35 and 55 foot-pounds.

7.5.28 Vent Valve, Inshot Piston, Emergency AcceleratedRelease Spool

7.5.29 Install a NEW inshot diaphragm (41) on the inshotpiston (43) so that the flat surface of the diaphragm whichshows the part number faces away from the piston.

7.5.30 Install the diaphragm follower (40) on the piston (43)so that the small diameter of the follower (40) is facing thediaphragm (41). Secure the follower (40) and the diaphragm(41) on the inshot piston (43) by installing a NEW 3/8-16 self-locking hex nut (39). Torque the nut to 9 to 12 foot-pounds.

7.5.31 Apply #2 Silicone Grease, Wabtec CorporationSpecification M-07680-02, to the surfaces of a NEW 3/8" O.D.o-ring (42). Also lightly lubricate the O-ring groove on theshaft of the inshot piston (43) and the bearing surfaces of theinshot piston bushing of the body (58).

7.5.32 Install the NEW lubricated 3/8" O.D. o-ring (42) intoits groove on the shaft of the inshot piston (43).

7.5.33 Install the inshot diaphragm piston assembly (39 to43) into the body (58). Be sure that the bead of the diaphragm(41) is properly seated in the bead groove of the body (58).

7.5.34 Install the inshot piston spring (38) over the nut (39)on the exposed end of the inshot piston (43) so that thespring seats in the diaphragm follower (40).

7.5.35 Using a foam-tipped swab applicator, evenlyspread a light coating of Triple Valve Oil, WabtecCorporation Specification M-07611-20 (AAR SpecificationM-912), to the large diameter surface of the stem of thevent valve piston (37). Carefully insert the vent valve piston(37) into the body (58).

7.5.36 Place a NEW vent valve piston diaphragm (36) onthe vent valve piston (37) ensuring that the part number onthe diaphragm faces the piston. With the aid of the handtool, shown in Figure 6, properly position the diaphragm(36) so that the loop of the diaphragm sits between the piston(37) and body (58).

7.5.37 Install a NEW 15/16" O.D. ring gasket (34) and a NEW5/8" O.D. ring gasket (35) in their grooves in the vent valvecover (33).

7.5.38 Place the vent valve cover (33) on the body (58) andinstall the two 1/2� x 11/8� hex head screws (31), the METALIDENTIFICATION TAG (29a), and the 1/2� x 13/4� hex headcap screw (32).

7.5.39 Small Vent Valve, Inshot Check Valve

7.5.40 Install a NEW inshot check valve (27) and the inshotcheck valve spring (26) into the body (58). Align properly andsecure these parts in place by installing the inshot springretainer (25).

7.5.41 Using a foam-tipped swab applicator, evenly spreada light coating of Triple Valve Oil, Wabtec CorporationSpecification M-07611-20 (AAR Specification M-912), to theouter diameter surfaces of the small vent valve piston (30).Install the small vent valve piston assembly (30) seal endfirst, into the body (58).

7.5.42 Install the small vent valve piston spring (29) into thesmall vent valve (30) and secure it in place by installing thespring retainer (28) in the body (58). Be sure that the retainer(28) is properly secured.


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Figure 13 - ABDX-SS Service Portion, Part No. 664743

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7.6 DISASSEMBLY of ABDX-SS SERVICE PORTIONSee Figures 13 & 14

7.6.1 Remove the release valve portion (54) from the body(49) by first removing the three 3/8" flanged hex nuts (52).

7.6.2 Remove and SCRAP the five 13/16" O.D. ring gaskets(56) and the 7/8" O.D. ring gasket (55) from the mounting faceof the release valve portion (54). Remove the wire meshstrainers (57) from the body (49).

7.6.3 Set the release valve portion (54) aside in a clean,protected area for later disassembly.

7.6.4 Service Diaphragm Piston

7.6.5 Remove the top cover (2) from the body (49) byremoving the four 1/2" x 13/4" hex head screws (1).

7.6.6 Remove and SCRAP the 11/16" O.D. ring gasket (3)from the top cover (2).

7.6.7 Carefully remove the service piston assembly(4 to 17) as a unit from the body (49).

7.6.8 Place the service piston assembly (4 to 17) on theService Piston Assembly fixture, Part No. 564522 as shownin Figure 8. Hold the service piston assembly in position sothat the slide valve spring (13) rests on the fixture with theseat of the slide valve (15) facing upward.

7.6.9 Using the driver pin that is furnished with the pistonholding fixture, carefully drift the 3/32" x 1" cylindrical springpin (11) from the slide valve (15).

7.6.10 Remove the slide valve spring (12), slide valve (15),graduating valve (14) and graduating valve spring (13) fromthe service piston (16).

7.6.11 Remove the 5/8" x 1" hex head cap screw (4) whichsecures the diaphragm follower (5) and diaphragm (6) to theservice piston (17).

7.6.12 Remove the diaphragm follower (5) and diaphragm(6) from the service piston (16). SCRAP the diaphragm (6).

7.6.13 Remove the spring seat retaining ring (7) from thetail of the service piston (16), then remove the spring seat(8), spring (9) and spring guide (10). Remove and SCRAPthe service piston rings (17) from the service piston (16).

7.6.14 Limiting Valve, Back Flow Check Valve

7.6.15 Remove the four 1/2" x 11/4" hex head screws (33)which secure the bottom cover (44) to the body (49).

WARNING: The bottom cover (44) is under spring load.Exercise care so that no parts are inadvertently expelledfrom the assembly. Inadvertently expelled parts may causebodily injury.

7.6.16 Remove the bottom cover (34) from the body (49).

7.6.17 Remove and SCRAP the 11/16" O.D. ring gasket (38),the 2" O.D. ring gasket (35) and the 2" flange fitting gasket(39) from the cover (34).

7.6.18 Remove the check valve spring (36) and the checkvalve (37) from the body (49). SCRAP the check valve (37).

7.6.19 Remove the brake cylinder limiting valve spring (42),diaphragm follower (43) and the brake cylinder limiting valvediaphragm (44) from the body (49).

7.6.20 Remove and SCRAP the o-rings (46 & 47) from thebrake cylinder limiting valve stem (45).

7.6.21 Remove the piston return spring (40) and the springcage (41) from the body (49).

7.6.22 Accelerated Service Release Valve

7.6.23 Remove the service accelerated release valve cover(19), wear protection disk (20), and diaphragm/pistonassembly (21 to 24) as a unit from the filling piece (31) byfirst removing the four 1/2" x 23/4" hex head screws (18).

7.6.24 Remove the service accelerated release valve piston/diaphragm assembly (21 to 24) from the cover (19).

7.6.25 Using the Service Accelerated Release Valve PistonSpanner Wrench, as shown in Figure 10, to hold the serviceaccelerated release valve piston (24), remove the 9/16" hexhead nut (21), diaphragm follower (22) and the diaphragm(23) from the threaded end of the piston (24). SCRAP thediaphragm (23).

NOTE: If required, use a flat bar placed in the slot to retainthe service accelerated release piston (24) while removingthe 9/16� hex head nut (21).


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Figure 14 - ABDX Release Valve Portion, Part No. 566198

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7.6.26 Remove the service portion filling piece, plunger,check valve assembly, and mounting gasket (25 to 32) as aunit from the body (49).

7.6.75 Remove and SCRAP the filling piece mountinggasket (32).

7.6.28 Compress and remove the spring seat (28), checkvalve spring (29), and accelerated release check valve (30)from the filling piece (31). SCRAP the check valve (30).

7.6.29 Remove the service accelerated release valve plungerwith o-ring (25, 26) by pushing it out of the cover end of thefilling piece (31). Remove and SCRAP the 1/4" O.D. o-ring(26) from the end of the plunger (25).

7.6.30 Remove and SCRAP the 11/16" O.D. ring gasket (27)from its groove in the filling piece.

7.6.31 Retrieve the release valve portion (54) which waspreviously set aside in a clean, protected area.

7.6.32 Disassembly of Release Valve PortionSee Figure 14

7.6.33 Remove the five 3/8" x 11/2" hex head screws (1) whichsecure the top cover (2) of the release valve portion to therelease valve body (35).

7.6.34 Remove the top cover (2) from the body (35).

7.6.35 Remove and SCRAP the two 1" O.D. ring gaskets(3) from their grooves in the top cover (2).

7.6.36 Remove the two check valve springs (12), theauxiliary and emergency reservoir check valves (13) and thetwo check valve plungers (14) from the body (35). SCRAPthe two check valves (13).

7.6.37 Remove the spool valve spring (4) from the body (35).

7.6.38 Remove the spool valve - diaphragm follower -diaphragm assembly (5 to 11) from the body (35) as a unit.

7.6.39 Remove and SCRAP the three 3/4" O.D. o-rings (11)from their grooves on the spool valve (10).

7.6.40 Using an open end wrench to hold the spool valve(10), remove the 3/8" self-locking nut (5), diaphragm follower

(6), diaphragm (7) and the piston with o-ring (8, 9) fromthe threaded end of the spool valve (10). Remove the 1/2"O.D. o-ring (9) from its groove in the piston (8). SCRAPthe o-ring (9), diaphragm (7) and the self-locking nut (5).

7.6.41 Remove and SCRAP the 3/16" x 2" cotter pin (24)which secures the release valve stem guard (25) to the stemand end plate (27). Remove the stem guard (25).

WARNING: The bottom cover (31) is under spring load.Exercise care so that no parts are inadvertently expelledfrom the assembly. Accidently expelled parts may causebodily injury.

7.6.42 Remove the five 3/8" x 13/4" hex head cap screws(15) that secure the bottom cover, valve seal, exhaust sealstem, and end plate assembly (27 to 33) to the body (35).Remove the cover assembly from the body (35).

7.6.43 Remove the stem and end plate (27), bottom covergasket (28), seal (30) and 5/8" O.D. ring gasket (29) from thecover (31). SCRAP the gaskets (28, 29) and seal (30).

7.6.44 Remove the lifter (26) and lifter spring (23) from thebody (35).

7.6.45 Remove the bottom cover sleeve (34) from the bottomcover (31).

7.6.46 Cut off the head of the 3/16" x 1/2" aluminum pop rivet(33) and remove the rivet (33) and seal (32) from the bottomcover (31). SCRAP the rivet (33) and seal (32).

7.6.47 Remove the retaining check valve (20) and its spring(19) from the body (35). SCRAP the check valve (20).

7.6.48 Remove the reset check valve spring (22) and thereset check valve (21) from the body (35). SCRAP the checkvalve (21).

7.6.49 Remove the reset spool valve with o-ring assembly(18, 17) and the reset spool valve spring (16) from thebody (35).

7.6.50 Remove and SCRAP the three 3/4" O.D. o-rings (17)from the reset spool valve (18).


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7.7 ASSEMBLY of ABDX-SS SERVICE PORTIONSee Figure 13

7.7.1 Service Diaphragm Piston

7.7.2 Install the service piston rings (17) on the servicepiston (16).

IMPORTANT: Care should be taken when expanding oropening the service piston rings during installation onto theservice piston. Do not overexpand the rings causing them todeform which would result in difficult installation of the pistoninto the bore. The service piston ring should be installed withthe gap facing the slide valve area of the service piston. Thepositioning of the rings will ease the assembly.

7.7.3 Position a NEW diaphragm (6) on the service piston(16) so that the part number on the diaphragm (6) faces awayfrom the piston (16). After positioning the diaphragm beadinto the groove of the piston, flip the diaphragm (6) so thatthe large cone shaped opening is facing the follower (5).

7.7.4 Position the diaphragm follower (5) on the diaphragm(6) and piston (16).

7.7.5 Lightly coat the threads of the 5/8" x 1" hex head capscrew (4) with Loctite Sealant TL-242, Wabtec CorporationSpecification M-07499-05. Install the cap screw (4) throughthe diaphragm follower (5) and into the piston (16) to securethe piston (16), diaphragm (6) and follower (5) together. Handtighten the cap screw (4) and flip the diaphragm (6) in theopposite direction so that the large cone shaped opening isfacing the piston (16). Torque the screw (4) between 45 and50 foot-pounds.

7.7.6 Using a foam-tipped swab applicator, evenly spreada light coating of Triple Valve Oil, Wabtec CorporationSpecification M-07611-20 (AAR Specification M-912) aroundthe surfaces of the piston spring guide (10) and the bearingsurfaces of the piston bushing.

7.7.7 Install the piston spring guide (10), closed end first,into the open end of the service piston (16).

7.7.8 Install the piston spring (9) and spring seat (8) intothe open end of the spring guide (10) and secure the parts inplace by installing the spring retainer (7).

7.7.9 Place the slide valve spring (12) on the holding fixture,Part No. 564522, as shown in Figure 8.

7.7.10 Using a foam-tipped swab applicator, evenlyspread a light coating of Triple Valve Oil, WabtecCorporation Specification M-07611-20, (AAR SpecificationM-912) on the face of the graduating valve (14) and overthe graduating valve seat of the slide valve (15).

7.7.11 Install the graduating valve spring (13), graduatingvalve (14), and slide valve (15) on to the piston (16).

7.7.12 Place the piston assembly on the slide valve spring(12) which is still in the holding fixture.

7.7.13 Make sure that the graduating valve (14) is on itsseat in the slide valve (15) and that the slide valve side wingsare down tight in the fixture.

7.7.14 Install the 3/32" x 1" cylindrical spring pin (11) throughthe pin holes of each of the wings of the slide valve (15) andthe aligned pin hole of the slide valve spring (13). With theaid of the pin driver supplied with the holding fixture, Part No.564522, secure the pin (11) in place.

7.7.15 Remove the assembly from the holding fixture.

7.7.16 Using a foam-tipped swab applicator, evenly spreada light coating of Triple Valve Oil, Wabtec CorporationSpecification M-07611-20 (AAR Specification M-912) over theface of the slide valve (15) and the service piston rings (17)on the service piston (16). Also apply a light coating of theTriple Valve Oil to the slide valve seat of its bushing in thebody (49), and to the collars and fins of the piston (16) nearthe piston head.

IMPORTANT: Care must be taken when compressing thegraduating valve and slide valve in preparation for insertingthe service piston assembly with rings (4 to 17) into the bodybushing. While using minimal force, the assembly must bealigned squarely to prevent any wedging or distortion. Theslide valve face (15) must be retracted from the bushing faceas long as possible. Care must be taken not to damage theslide valve seats.

7.7.17 Install the piston - diaphragm - slide valve assembly(4 to 17) into the body (49) from the top, exercising care sothat NO damage is done to the slide valve seat.


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7.7.18 Using only finger and thumb pressure, position thesealing bead of the diaphragm (6) into the diaphragm beadgroove on the top cover mounting face of the body (49).

7.7.19 Install a NEW 11/16" O.D. ring gasket (3) into itsgroove in the top cover (2).

7.7.20 Insert two guide pins into two diagonally oppositethreaded holes of the body (49). Using the pins as guides,position the cover assembly (2, 3) onto the body (49). In theremaining two threaded holes, tighten by hand, two 1/2" x 13/4"hex head cap screws (1). Remove the two guide pins andinstall the other two 1/2" x 13/4" hex head cap screws (1). Torqueall four cap screws between 35 and 55 foot-pounds.

7.7.21 Limiting Valve, Back Flow Check Valve

7.7.22 Using a foam-tipped swab applicator, evenly spreada light coating of Triple Valve Oil, Wabtec CorporationSpecification M-07611-20 (AAR Specification M-912) aroundthe collar on each end of the spring cage (41).

7.7.23 Install the piston return spring (40) into the springcage (41), then install the cage with spring (41, 40) as a unitinto the body (49) so that the spring (40) goes over and aroundthe end of the shaft of the piston (16), which has alreadybeen installed.

7.7.24 Position a NEW diaphragm (44) onto the brakecylinder limiting valve stem (45) so that the flat surface of thediaphragm, which shows the part number, faces away fromthe stem towards the threaded end.

7.7.25 Using #2 Silicone Grease, Wabtec CorporationSpecification M-07680-02, lubricate the surfaces of two NEWo-rings (47, 46). Also lightly lubricate the o-ring grooves onthe shaft of the stem (45) and the bearing surfaces of thepiston bushing in the body (49).

7.7.26 Install the spring, stem and diaphragm (45 to 48)into the body (49), o-ring end first. Be sure that the bead ofthe diaphragm (44) is properly seated in its groove in thebody (49). Use finger pressure to seat the bead.

7.7.27 Install the diaphragm follower (43) and brake cylinderlimiting valve spring (42) into the body (49) so that it seats onthe diaphragm follower (44).

7.7.28 Install a NEW back flow check valve (37) andthe check valve spring (36) into the proper cavity of thebody (49).

7.7.29 Install a NEW 2" flange fitting gasket (39), a NEW2" O.D. ring gasket (35) and a NEW 11/16" O.D. ring gasket(38) into their grooves in the bottom cover (34).

7.7.30 Carefully position the bottom cover assembly (34,35, 38 and 39) on the body (49) making sure that all gasketsand assemblies of the body are properly in place. Securethe bottom cover (34) to the body (49) by installing four 1/2" x11/4" hex head screws (33). Equally torque the screwsbetween 35 and 55 foot-pounds.

7.7.31 Accelerated Service Release Valve

7.7.32 Install a NEW accelerated release check valve (30)into the service portion filling piece (31).

7.7.33 Install the check valve spring (29) into the filling piece(31) so that it seats on the check valve (30), then install thespring seat (28) to retain the parts in place.

7.7.34 Place a NEW filling piece gasket (32) and the serviceportion filling piece (31) in position on the body (49).

7.7.35 Apply a light coating of #2 Silicone Grease, WabtecCorporation Specification M-07680-02, to the surfaces of aNEW 1/4" O.D. o-ring (26). Also lightly lubricate the o-ringgroove on the service accelerated release valve plunger (25)and the bearing surfaces of the plunger bushing of the fillingpiece.

7.7.36 Install the NEW lubricated 1/4" O.D. o-ring (26) intoits groove on the short end of the service accelerated releasevalve plunger (25), then install the plunger with o-ring (26, 25)into the filling piece (31), longer end of the plunger first.

7.7.37 Using the Accelerated Release Valve Piston SpannerWrench, as shown in Figure 10, to hold the serviceaccelerated release valve piston (24), install a NEWdiaphragm (23) onto the piston (24) so that the part numberon the diaphragm faces away from the piston toward thethreaded end.

7.7.38 Install the diaphragm follower (22) and lightly coatthe threads of the service accelerated release valve piston


August, 2003 of 24

4225-50, S.6

(24) with Loctite Sealant TL-242, Wabtec CorporationSpecification M-07499-05. Install the 9/16" nut (21) on thethreaded end of the piston (24) and torque the nut (21) between40 and 55 foot-pounds.

7.7.39 Install the diaphragm - piston assembly (21 to 24),piston end first into the filling piece (31). Be sure that thebead of the diaphragm is properly seated in its groove on thefilling piece (31). Use finger pressure to properly seat thediaphragm bead.

7.7.40 Install the wear protection disk (20) over the hex nut(21). The disc lies on the follower (22) and is not held inplace by any means. The body will have to be positioned sothe disc remains in place while installing the cover (19).

7.7.41 Install a NEW 11/16" O.D. ring gasket (26) into itsgroove on the cover mounting face of the filling piece (30).

7.7.42 Place the service accelerated release valve cover(19) in position on the filling piece (30). Be sure that all partsare properly positioned, then using the four 1/2" x 23/4" hexhead screws (18), secure the cover and filling pieceassemblies (19 to 31) to the body (49). Equally torque thescrews (18) between 35 and 55 foot-pounds.

7.7.43 Release Valve Portion AssemblySee Figure 8

7.7.44 Using #2 Silicone Grease, Wabtec CorporationSpecification M-07680-02, lightly lubricate the surfacesof three NEW 3/4" O.D. o-rings (17). Also lightly lubricatethe o-ring grooves of the spool valve (18) and the bearingsurfaces of the spool valve bushing of the release valveportion body (35).

7.7.45 Install the three NEW lubricated 3/4" O.D. o-rings(17) into their grooves on the spool valve (18).

7.7.46 Install the spool valve spring (16) and spool valve witho-ring assembly (17, 18) into the release valve body (35).

7.7.47 Install the lifter spring (23) and lifter (26) into theproper cavity in the release valve body (35).

7.7.48 Install a NEW reset check valve (21) and the checkvalve spring (22) into the proper cavity of the release valvebody (35).

7.7.49 Install the check valve spring (19) and a NEWretaining check valve (20) in the proper cavity of the releasevalve body (35). The seat for the retaining check valve islocated in the bottom cover.

7.7.50 Install the bottom cover sleeve (34) and secure aNEW seal (32) with a NEW 3/16" x 1/2" aluminum pop rivet(33) in the bottom cover (31).

7.7.51 Install a NEW valve seal (30), stem and end plate(27), a NEW 5/8" O.D. ring gasket (29) and a NEW bottomcover gasket (28) in place in or on the bottom cover (31).

7.7.52 Carefully position the bottom cover assembly (27 to34) on the body (35) without applying heavy pressure, theninsert the five 3/8" x 13/4" hex head cap screws (15) into thecover (31). Observe the retaining check valve (20) to be surethat it is in alignment with the check valve seat in the cover(31). Also be sure that the reset check valve spring (22) isproperly positioned in the cover (31), then hand press thecover (31) to the body (35) and secure it in place by equallytightening the five 3/8" x 13/4" hex head cap screws (15) to atorque value between 15 and 25 foot-pounds.

7.7.53 Using #2 Silicone Grease, Wabtec CorporationSpecification M-07680-02, lightly coat the surfaces of a NEW1/2" O.D. o-ring (9) and three NEW 3/4" O.D. o-rings (11). Alsolightly coat the o-ring grooves on the spool valve (10) and thebearing surfaces of the spool valve bushing of the body (35).

7.7.54 Using an open end wrench to hold the spool valve(10), install the piston (8) on the threaded end of the spoolvalve (10).

7.7.55 Install the NEW lubricated 1/2" O.D. o-ring (9) inplace on the piston (8), then install a NEW diaphragm (7) sothat the part number on the diaphragm faces away from thepiston toward the threaded end of the spool valve (10).

7.7.56 Install the diaphragm follower (6) and a NEW 3/8-16self-locking hex nut (5) on the threaded end of the spoolvalve (10). Secure the parts together by torquing the nut (5)to 12 to 14 foot-pounds.

7.7.57 Install the three NEW lubricated 3/4" O.D. o-rings(11) into the three o-ring grooves of the spool valve (10).

7.7.58 Install the diaphragm piston assembly (5 to 11) intothe body (35). Be sure that the bead of the diaphragm (7) is


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properly seated in the bead groove of the body (35). Usefinger pressure to seat the bead in the groove.

7.7.59 Install the spool valve spring (4) in the body (35) sothat it is seated on the diaphragm follower (6).

7.7.60 Install the emergency and auxiliary reservoir checkvalve plungers (14) into the proper cavities of the body (35).

7.7.61 Install two NEW check valves (13) into the body (35)on top of the two plungers (14), then install the two checkvalve springs (12).

7.7.62 Install two NEW 1" O.D. ring gaskets (3) into theirgrooves in the top cover (2).

7.7.63 Carefully place the top cover assembly (2, 3) ontothe body (35) being sure that the springs (4 and 12) areproperly positioned in the spring cavities of the cover. Securethe top cover (2) to the body (35) by installing the five 3/8" x11/2" hex head cap screws (1). Equally torque the screwsbetween 15 and 25 foot-pounds.

7.7.64 Install three cleaned wire mesh filter screens (57) inplace in the release valve portion body (48).

7.7.65 Install a NEW 7/8" O.D. ring gasket (55) and five NEW13/16" O.D. ring gaskets (56) into their grooves on the mountingface of the release valve portion (58).

7.7.66 Place the release valve portion (58) on the serviceportion body (48) and secure it in place by installing three3/8" flanged hex nuts (53). Equally torque the nuts between11 and 30 foot-pounds.

7.7.67 The release valve stem guard (25) is to be installedafter the service portion has been tested. Use a NEW 3/16� x2� cotter pin (24) when installing the guard (25).

7.8 CLEANING & INSPECTING

7.8.1 NON-REUSABLE PARTS

IMPORTANT: ALL gaskets, o-rings, self-locking or elasticstop nuts, diaphragms and wear rings ARE TO BESCRAPPED AND REPLACED WITH NEW WABTECCORPORATION PARTS.

7.8.2 REUSABLE PARTS

7.8.2.1 Wash ALL reusable parts in the cleaning solventdescribed in Section 6. Springs may be wire brushed to assistin the removal of any dirt, rust or scale. Care must be takennot to damage springs.

IMPORTANT: Cleaning solvents are to be used in awell ventilated area.

7.8.2.2 The operating portions must be completelydismantled and all parts inspected and cleaned. Parts,including the body interior, must be cleaned by an approvedmethod that will dissolve oil and grease without damage tothe parts. The body must not be submerged in a solution. Awire brush may be used to assist in the removal of any lightsurface dirt, rust or scale on cast parts. The exterior of thebody must be thoroughly cleaned.

7.8.2.3 All pistons, slide valves, graduating valves andbushings must be thoroughly cleaned. To do this, the piston,slide valve and graduating valve assembly must bedismantled.

7.8.2.4 After the parts have been cleaned, they MUST BEcompletely dried. Use a low pressure jet of clean, dry air toblow the parts dry.

8.0 TESTING AND ADDITIONAL INFORMATION

8.1 After the ABDX-SS Control Valve has beenassembled, but before it has been returned to service, it mustpass a series of tests following the procedures of the currentissue of Wabtec Corporation Test Specification T-664742A/B-O.

8.2 IMPORTANT: The ABDX-SS portions are not tobe applied to cars exceeding 39 feet in length. Extremecaution musty be taken to ensure the portions replace likeportions on the car. Failure to heed these instructions mayresult in equipment damage and/or personal injury.

8.3 IMPORTANT: When installing the Emergency,Service or both Portions on the ABDX-SS Pipe BracketPortion, NEW gaskets and filters must be used, seeSection 7.2.


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Figure 16 - Release Valve Stem Guard

Figure 15 - Shipping Covers

Figure 17 - Vent Protector Plug


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WABCO Freight Car Products1001 Air Brake Avenue www.wabtec.com 475 Seaman StreetWilmerding, Pennsylvania 15148 Stoney Creek, Ontario L8E 2R2(412) 825-1000 � Fax (412) 825-1019 (905) 561-8700 � Fax (905) 561-8705

8.4 IMPORTANT: Whenever the Emergency orService Portion is removed from an equipment arrangement,for any reason, and it is reinstalled or replaced with a NEWor REPAIRED and TESTED Portion, the ABDX-SS ControlValve must be tested to ensure that it works properly inconjunction with the remainder of the brake equipment.

8.5 Consult your Wabtec Corporation representative ifadditional information is required.

operation & maintenance instruction

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